We machine flat aluminum bar stock into high-end electronics housings. Usually start with AL slugs around the size of a pack of cigarettes.
Right now I use a chop-saw with a carbide tipped blade that goes through the AL like butter. $99 for the saw at Home Depot and $60 for a fancy "Diablo" blade. Problem is that it's hard to get it super accurate (i.e. you're always eyeballing the blade kerf). Also, it scares the crap out of me with that big blade zipping around so fast. And don't try to keep cutting when the bar stock gets short - it can and will (and has) thrown pieces of the stock across the shop on occasion and I've busted knuckles and bloodied my fingers when the flying AL catches them.
I can get a metal cutting band saw but now sure how accurate that would be.
Or... I was thinking a cold saw? I have heard you can get accurate cuts to within several thou if you set it up right. I don't need it to be THAT accurate (I'd be happy if I could keep 1/64") but the blade moving slower and better able to cut smaller pieces, and much less chance to throw metal pieces around would be good.
Any suggestions? I'll keep using the chop saw but soon I want to get something else that will be quick, efficient, SAFE, accurate, and will last me a long time.